Reversing valve

ABSTRACT

A reversing valve comprising a valve body having an internal cavity therein and an input port, output port and first and second reversing ports. A baffle is located within the internal cavity and is configured to rotate around a pivot point within the internal cavity. At least one electromagnet is coupled to the valve body. The electromagnet is configured to cause the baffle to rotate in one of the clockwise direction or counter-clock wise direction when a voltage is applied to the electromagnet.

TECHNICAL FIELD

This application is directed, in general, to space conditionalapparatuses and, more specifically, to a reversing valve, and to amethod of manufacturing thereof.

BACKGROUND

A reversing valve is often used in heat pumps to facilitate the changingthe direction of refrigerant flow and thereby change the heat pump'srefrigeration mode between cooling and heating. Typically the reversingvalve includes or is coupled to a solenoid that when energized, causesthe refrigerant to flow in one direction, and when de-energized, causethe refrigerant to flow in another direction.

SUMMARY

One embodiment of the present disclosure is a reversing valve. The valvecomprises a valve body having an internal cavity therein and an inputport, output port and first and second reversing ports, wherein theinput port, the output port and the first and second reversing ports areall in fluid communication with the internal cavity. The valve alsocomprises a baffle located within the internal cavity. The baffle isconfigured to rotate around a pivot point within the internal cavity.Ends of the baffle contact interior walls of the value body when thebaffle rotates about the pivot point in a clockwise direction, therebyisolating the input port and first reversing port and volume of theinternal cavity there-between, from the output port and second reversingport and different volume of the internal cavity there-between. The endsof the baffle contact different interior walls of the value body whenthe baffle rotates about the pivot point in a counter-clock wisedirection, thereby isolating the input port and the second reversingport and second volume of the internal cavity there-between from theoutput port and the first reversing port and second different volume ofthe internal cavity there-between. The value also comprises at least oneelectromagnet coupled to the valve body. The electromagnet is configuredto cause the baffle to rotate in one of the clockwise direction orcounter-clock wise direction when a voltage is applied to theelectromagnet.

Another embodiment of the discloser is a heat pump system. The systemcomprises an indoor heat exchanger, an outdoor heat exchanger, acompressor and the above-described reversing valve. The compressor isconfigured to compress a refrigerant and configured to transfer therefrigerant to a discharge line of the system and to receive therefrigerant from a suction line of the system. The input port is coupledto the discharge line, the output port is coupled to the suction line,the first reversing port is coupled to a transfer line connected to theoutdoor heat exchanger, and the second reversing port is coupled to asecond transfer line connected the indoor heat exchanger.

Another embodiment is method of manufacturing a reversing valve. Themethod comprises providing a valve body having an internal cavitytherein and an input port, output port and first and second reversingports, wherein the input port, the output port and the first and secondreversing ports are all in fluid communication with the internal cavity.The method also comprises providing a providing a baffle configured tofit within the internal cavity. The baffle is provided such that baffleis configured to rotate around a pivot point within the internal cavity.Ends of the baffle contact interior walls of the value body when thebaffle rotates about the pivot point in a clockwise direction, therebyisolating the input port and first reversing port and volume of theinternal cavity there-between, from the output port and second reversingport and different volume of the internal cavity there-between. The endsof the baffle contact different interior walls of the value body whenthe baffle rotates about the pivot point in a counter-clock wisedirection, thereby isolating the input port and the second reversingport and second volume of the internal cavity there-between from theoutput port and the first reversing port and second different volume ofthe internal cavity there-between.

The method further comprises coupling at least one electromagnet to thevalve body, wherein the electromagnet is configured to cause the baffleto rotate in one of the clockwise direction or counter-clock wisedirection when a voltage is applied to the electromagnet.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference is now made to the following descriptions taken in conjunctionwith the accompanying drawings, in which:

FIG. 1 presents a perspective view of an example reversing valve of thedisclosure;

FIG. 2 presents a perspective view of an example reversing valve of thedisclosure, similar to the example embodiment showed in FIG. 1 exceptwith some parts of the valve body not show so that some internalfeatures are visible.

FIG. 3A shows a plan view of an example reversing valve of thedisclosure, similar to the example embodiments depicted in FIGS. 1 and2, with full clockwise baffle rotation;

FIG. 3B shows a plan view of an example reversing valve of thedisclosure, similar to the example embodiments depicted in FIGS. 1 and2, with full counter-clockwise baffle rotation;

FIG. 3C shows a detailed view of a portion of the reversing valve 100shown in FIG. 3A;

FIG. 4 shows a plan view of selected portions of another exampleembodiment of the reversing valve of the disclosure similar to thatdepicted in FIGS. 3A and 3B;

FIG. 5 shows a plan view of selected parts of another example embodimentof the reversing valve of the disclosure, similar to that depicted inFIG. 4, showing the baffle rotated counter-clockwise and depictingexample refrigerant flow directions through the reversing valve for theembodiment;

FIG. 6 shows a plan view of selected parts of another example embodimentof the reversing valve of the disclosure, similar to that depicted inFIG. 4, showing the baffle rotated clock wise and depicting examplerefrigerant flow directions through the reversing valve for theembodiment;

FIG. 7 show a block diagram of an example heat pump system of thedisclosure;

FIG. 8 presents a flow diagram of an example method of assembling areversing valve disclosure, including any of the example embodimentreversing valve discussed in the context of FIGS. 1-7.

DETAILED DESCRIPTION

The term, “or,” as used herein, refers to a non-exclusive or, unlessotherwise indicated. Also, the various embodiments described herein arenot necessarily mutually exclusive, as some embodiments can be combinedwith one or more other embodiments to form new embodiments.

Embodiments of the present disclosure benefit from the recognition thatsome reserving valve designs rely on the combination of moving a slidingassembly by an energizing (or de-energizing) a solenoid which causes anapplied pressure from refrigerant through pressure ports to push slidingcomponent, and thereby accomplish a change in direction of refrigerantflow through the valve. It was recognized as part of the presentdisclosure, that an industry-wide trend towards using low-speed andlow-pressure compressors, reduces the reliably of such valve designs.For instance, when the applied pressure from refrigerant flowing intothe valve is reduced, the sliding assembly can become stuck in-betweenfully actuated states, corresponding to a partial change in thedirection of refrigerant flow. Consequently, the efficiency of thecooling mode or heating mode of the heat pump can be compromised.

Embodiments of the present disclosure address this problem by providinga reversing valve that can cause full valve actuation by applying anelectromagnetic force that causes an internal baffle to rotate tofacilitate the change in direction of refrigerant flow through thevalve. Reversing valve embodiments of the disclosure can fully actuatewithout relying upon having a high pressure of inflowing refrigerant, orin some cases, any refrigerant pressure whatsoever.

Certain reversing valve embodiments of the disclosure can also have anumber of additional unexpected beneficial features that were notpresent in other valve designs. Because high-pressures of refrigerantflowing through the value are not required for valve actuation, there isless acoustical noise associated with actuation. There is no longer aneed to use a sliding assembly, or the small diameter pressure porttubing to push the sliding assembly. The elimination of the smalldiameter pressure port tubing, in turn, eliminates the possibility ofthe tubing getting clogged up with debris (e.g., solder flakes, orcompressor shavings) and thereby causing a valve malfunction. The choiceof the material that the baffle is composed of can facilitate less heattransfer across the baffle and hence more efficient operation of theheat pump. Certain embodiments of the disclosed reversing valve can havewell-separated inlet, outlet and reversing port locations as part of thevalve body, which in turn, facilitates in-field replacement of thevalve.

One embodiment of the present disclosure is a reversing valve 100 suchas depicted in FIGS. 1-3B. FIG. 1 presents a perspective view of anexample reversing valve 100 of the disclosure and shows a similarperspective view an example reversing valve 100 except with some partsof a valve body not show so that some internal features are visible.FIGS. 3A and 3B show plan views of an example reversing valve 100 of thedisclosure, similar to the example embodiments depicted in FIGS. 1 and 2with full clockwise and counter-wise baffle rotation respectively, andFIG. 3C shows a detailed view of a portion of the reversing valve 100shown in FIG. 3A.

With continuing reference to FIGS. 1-3C throughout, the reversing valve100 comprises a valve body 105. The valve body 105 has an internalcavity 205 therein, and, an input port 210, output port 212 and firstand second reversing ports 214, 216. The input port 210, the output port212 and the first and second reversing ports 214, 216 are all in fluidcommunication with the internal cavity 205.

The reversing valve 100 also comprises a baffle 220 located within theinternal cavity 205. The baffle 220 is configured to rotate around apivot point 225 within the internal cavity 205. Ends 305, 307 of thebaffle 220 contact interior walls 310, 312 of the value body 105 whenthe baffle rotates about the pivot point 225 in a clockwise direction(FIG. 3A), thereby isolating the input port 210 and first reversing port214 and volume 320 of the internal cavity 205 there-between, from theoutput port 212 and second reversing port 216 and different volume 322of the internal cavity 205 there-between. For example, when rotated inthe clockwise direction, the ends 305, 307 of the baffle 220 sweep pastthe input port 210 and output port 212, respectively.

The ends 305, 307 of the baffle 220 contact different interior walls314, 316 of the value body 105 when the baffle 220 rotates about thepivot point 225 in a counter-clock wise direction (FIG. 3B), therebyisolating the input port 210 and the second reversing port 216 andsecond volume 324 of the internal cavity 205 there-between from theoutput port 212 and the first reversing port 214 and second differentvolume 326 of the internal cavity 205 there-between. For example, whenrotated in the counter-clockwise direction, the ends 305, 307 of thebaffle 220 sweep past the input port 210 and output port 212,respectively.

The reversing valve 100 also comprises at least one electromagnet 330coupled to the valve body 105. In some cases the electromagnet isembedded in the valve body 105 such as depicted in FIGS. 3A and 3B,while in other cases the electromagnet can be coupled to the outersurface 110 of the valve body 105. The electromagnet 330 is configuredto cause the baffle 220 to rotate in one of the clockwise direction orcounter-clock wise direction when a voltage is applied to theelectromagnet 330. For example, in some embodiments, the electromagnet330 includes a solenoid that is configured to receive about 24 volts toactivate the electromagnet 330 and generate a magnetic field that causesthe baffle 220 to rotate. One skilled in the art would be familiar withthe other types of electromagnets configurations and voltages that couldbe applied to achieve the desired rotation.

The example valve body 105 depicted in FIG. 1 has an octagonal shape inthe plan view dimension, and this shape can facilitate locating ports ofthe body on planar symmetrically spaced planar surfaces 110 of the body105. However, other embodiments of the body 105 could have other shapes,such as, but not limited to, cylindrical, cubic, rectangular prism,parallelapiped shapes or irregular shapes.

As further illustrated in FIGS. 1-3B, in some embodiments, the input andoutput ports 210, 212 are located on opposing sides 120, 122 of thevalve body 105 and the first and second reversing ports 214, 216 arelocated on different opposing sides 124, 126 of the valve body 105. Sucha symmetric spacing of the ports 210, 212, 214, 216 can improve accessto refrigerant transfer lines, 130, 132, 134, 136, respectively coupledto the individual ports 210, 212, 214, 216. Improved individual accessto the lines, 130, 132, 134, 136, in turn can facilitate fieldinstallation or replacement of the reversing valve 100, e.g., by makingit easier to solder or de-solder an individual tube from a port of thevalve 100.

As also illustrated in FIGS. 1-3B, in some embodiments, the ports210-216 are all in a common plane. Such a configuration can be conduciveto keeping the ports 210-216 and tubing 130-136 connected thereto,well-separated while also minimizing the total volume occupied by thevalve 100, e.g., by minimizing the valve structures or coupled lines inthe space above an below the common plane. Such a configuration canfacilitate installing the valve 100 in proximity to other components ofa space conditional system (e.g., a heat pump system) that the valve 100is part of. However in other embodiments of the valve 100, one or moreof the ports 210-216 can be on a same side 120-126, or, not all in acommon plane, or the valve 100 can include additional input, output orreversing ports.

As illustrated in FIGS. 2 and 3A-3C, in some embodiments of the valve100, one or more of the interior walls 310-316 can include recesses 230.Each recess 230 is configured such that a portion 330 of a major surface335 of the baffle 220 near one of the ends 305 of the baffle 220contacts the recessed portion 230 of one of the interior walls 310.Configuring the recess 230 to allow the major surface 335 to contact theinterior walls improving the fluid seal between the baffle 220 and theinterior wall 310 so as to better isolate the different volumes 320, 322of the chamber 105.

As further illustrated in FIG. 3C, to facilitate improving the fluidseal between the baffle 220 and the interior wall 310, some embodimentsof the baffle 220 and internal chamber 205 are shaped (e.g., viabending, milling or molding) so that the baffle edges opposing theinterior wall 310 (including top, bottom and sides of the chamber 105)are in close proximity to each other. That is the outer edge 340 of thebaffle 220 closely mirrors the surface contours of the internal cavity105. For example in some embodiments, a gap distance 345 between outeredges (e.g., edge 340) of the baffle 220 and the interior walls (e.g.,wall 310) is about ⅛ inch or less, and in some cases, about 1/16 inch orless.

In some embodiments, to facilitate the fluid seal between the baffle 220and the interior wall 310, the outer edge 340 of the baffle 220 (e.g.,all edges 340 of the baffle that oppose an interior wall of the chamber)remain in contact with the interior wall 310. as the baffle 220 rotates.In some such embodiments, at least the outer edge 340 of the baffle 220is covered with a pliable material 350 that contacts the interior wall310. The pliable material 350 can facilitate the baffle edge 340maintaining contact with the interior wall 310 as the baffle 220rotates, and can help mitigate wearing down of the baffle edge 340 orthe interior wall 310. Non-limiting example embodiments of the pliablematerial 350 include Teflon, Nylon, Carbon fiber or similar pliablematerials that can tolerate the high pressures and temperatures ofrefrigerant flowing through the value (e.g., up to about 450 psi and220° F. in some embodiments). In some embodiments, the entire baffle 220is coated with the pliable material 350. Such embodiments can mitigatethe pliable material 350 delaminating from the baffle 220, as comparedto when the pliable material is 350 only along the edge 340 of thebaffle 220.

In some embodiments, to facilitate the fluid seal between the baffle 220and the interior wall 310, the internal cavity 205 of the valve body 105is covered with a pliable material 355. For instance, as furtherillustrated in FIG. 3C, the interior walls (e.g., wall 310) can becoated with a pliable material 355. Any of the materials (e.g., Teflon,Nylon, Carbon Fiber) discussed in the context of the pliable material350 can also be used as the pliable material 355 associated with thevalve body 105. In some embodiments the valve body 105 can besubstantially composed of the pliable material.

In some embodiments of the baffle 220, to facilitate rotation of thebaffle 220 when the electromagnet 330 activated by applying the voltage,the baffle 220 is substantially composed of a ferromagnetic material.For instance, in some cases, the baffle 220 is made of entirely of aferromagnetic material such as iron, a low grade stainless steel (e.g.,grade 409 stainless steel or lower) or similar metals, or metal alloyscontaining ferromagnetic materials (e.g., in some cases at least about50 percent, in some case at least about 75 percent iron, by weight).

In other cases, however, the baffle 220 is substantially composed of anon-ferromagnetic material and further includes a ferromagnetic materialattached thereto. For example, in some embodiments, the baffle 220 canbe composed of Teflon or Nylon and further include a strip or layer 360of low grade stainless steel, or similar ferromagnetic material attachedthereto, in some cases near the baffle's ends 305, 307.

FIG. 4 shows a plan view of selected portions of another exampleembodiment of the reversing valve of the disclosure similar to thatdepicted in FIGS. 3A and 3B. As noted above, the reversing valve 100comprises at least one electromagnet 330. In some embodiments, such aswhen the reversing valve 100 has only one electromagnet 330, the pivotpoint 225 can be connected to a spring 410. Embodiments of the spring410, can be, or include, a spring coil, one or more torsion bars, orother spring mechanisms as familiar to those skilled in the art, capableof imparting a rotational torque on the baffle 220. The spring 410 isconfigured to rotate the baffle 220 to one of the clock-wise or counterclock-wise directions, and the electro-magnet 330, is configured torotate the baffle in the opposite one of the clock-wise orcounter-clock-wise directions. For instance, in the absence of theapplied voltage, the spring 330 may rotate the baffle 220 fullyclockwise until it is stopped by the interior wall 310 or the optionalrecess 230 therein. In the presence of the applied voltage, theelectromagnet 330 is activated and rotates the baffle counter-clockwiseuntil it is stopped by the interior wall 314 or other optional recess230 therein.

As further illustrated in FIGS. 3A-3B and 4, in some embodiments thepivot point 225 is substantially offset from the center of the internalcavity 205, along a central axis (e.g., axis 420 in FIG. 4) along theinput port 210 and the output port 212. In some cases, the pivot point225 (e.g., FIG. 4), e.g., past a central axis 430 along the first andsecond reserving ports 214, 216 towards to output port 212, that is,nearer to the output port 212 than the input port 210, and running alongthe central axis 420 along the input port 210 and the output port 212.In other cases, the pivot point 225 can be closer to the input port 210(e.g., FIG. 3A-3B). These offset locations of the pivot points 225 arenot specific to the example embodiment valves 100 depicted in FIGS.3A-4. For instance, in other cases the pivot point 225 depicted in FIG.4 is closer to the input port 210, e.g., past a central axis 430 alongthe first and second reserving ports 214, 216, nearer to the input port210 than the output port 212, and along the central axis 420 runningalong the input port 210 and the output port 212. In still otherembodiments, however, the pivot point 225 can be centrally located inthe internal cavity 205, e.g., along both of the central axes 420, 430depicted in FIG. 4.

Off-setting the location of the pivot point 225 as discussed above canfacilitate the optional use of pressure from the refrigerant runningthrough valve 100 to help rotate the baffle 330 in a particulardirection. For example, consider a state of operation of the valve 100where the pressure from refrigerant flow at the input port 210 issubstantially greater than the pressure of refrigerant flow at theoutput port 212 or reversing ports 214, 216. In such a state, thegreater pressure from the refrigerant flow into the input port 210 willassist the rotation of the baffle by applying more torque to the largersurface area 440 of the baffle on one side of the pivot point 225 ascompared to the smaller surface area 445 of the baffle on the other sideof the pivot point 225. For instance, once the ends 305, 307 of thebaffle 220 are rotated past the axis 420, or past the input port 210,the pressure from refrigerant flow at the input port 210 will helprotate in that same direction of rotation. In some embodimentstherefore, it may not be necessary to continuously apply the voltage tothe electromagnet 330 to complete the rotation of the baffle 220.

Some embodiments of the reversing valve comprise more than oneelectromagnet 330, and may or may not include the optional spring-loadedpivot point 225. FIGS. 5 and 6 show a plan views of selected portions ofsuch example embodiments of the reversing valve 100, similar to thatdepicted in FIG. 4, showing the baffle 220 rotated counter-clockwise andclockwise, respectively.

FIGS. 5 and 6 further depict example refrigerant flow directions throughthe reversing valve for the embodiments, assuming the refrigerantpressure at the input port is greater than the pressure at the outputport 212 and the pressures at the first and second reversing ports 214,216 are in-between the pressures at the input and output ports 210, 212.For example, the input port 210 can be configured to be coupled to arefrigerant discharge line from a compressor, the output port 212 can beconfigured to be coupled to a refrigerant suction line of thecompressor, and the first and second reversing ports 214, 216 areconfigured to be coupled to an outdoor heat exchange coil and an indoorheat exchange coil, respectively.

As illustrated in FIG. 5, in some embodiments, the electromagnet 330 isa first electromagnet configured to rotate the baffle 220 in one of theclockwise direction or the counter-clock wise direction, and the valve100 further includes a second electromagnet 510 coupled to the valvebody 105 and configured to rotate the baffle 220 in the opposite one ofthe clockwise direction or the counter-clock wise direction, when thevoltage is applied to the second electromagnet 510 and the voltage isnot applied to the first electromagnet 330. FIG. 5 shows the exampleembodiment valve 100 with the voltage applied to the first electromagnet330 and not applied to the second electromagnet 510, resulting in thebaffle 220 rotating counter-clockwise. In such a state, the refrigerantflow is directed from the input port 210 to the second reversing port216, and the refrigerant flow is directed from the first reversing port214 to the output port 212.

As illustrated in FIG. 6, some embodiments of the valve 100 include aplurality of electromagnets 330, 510, 610, 620 each coupled to the valvebody 105. A first set of the electromagnets (e.g., electromagnets 330,620) are configured to rotate the baffle 220 in one of the clockwisedirection or the counter-clock wise direction (e.g., counter-clockwise,in this example) when the voltage is applied to the first set ofelectromagnets and the voltage is not applied to a second set of theelectromagnets (e.g., electromagnets 510, 610). The second set ofelectromagnets are configured to rotate the baffle 220 in the oppositeone of the clockwise direction or the counter-clock wise direction(e.g., clockwise, in this example) when the voltage is applied to thesecond set of electromagnets and the voltage is not applied to the firstset electromagnets. As further illustrated in FIG. 6, in someembodiments the first set of electromagnets includes the electromagnet330 and a second electromagnet 620 diagonally opposed to theelectromagnet 330, and, the second set of electromagnets includes athird electromagnet 510 and a fourth electromagnet 620 diagonallyopposed to the third electromagnet 510. In such a state, the refrigerantflow is directed from the input port 210 to the first reversing port214, and the refrigerant flow is directed from the second reversing port216 to the output port 212.

Another embodiment of the disclosure is a heat pump system. FIG. 7 showa block diagram of an example heat pump system 700 of the disclosure.The heat pump system 700 can be configured as a space conditioningsystem for residential or commercial HVAC, or other space conditioningsystems well known to those skilled in the art. As illustrated in FIG.7, the system 700 comprises an outdoor heat exchanger 710, an indoorheat exchanger 715, and a compressor 720 configured to compress arefrigerant and configured to transfer the refrigerant to a dischargeline 130 and to receive the refrigerant from a suction line 132 of thesystem 700. The system 700 further includes the reversing valve 100,which can include any of the embodiments of the reversing valve 100discussed in the context of FIGS. 1-6. The input port 210 is coupled tothe discharge line 130, the output port 212 is coupled to the suctionline 132, the first reversing port 214 is coupled to a first transferline 134 connected to the outdoor heat exchanger 710, and the secondreversing port 216 is coupled to a second transfer line 136 connectedthe indoor heat exchanger 715.

For example, the first reversing port 214 can be coupled via firsttransfer line 134 to a heat exchange coil 740 of the outdoor heatexchanger 710. For example, the second reversing port 216 can be coupledvia second transfer line 136 to a heat exchange coil 745 of the indoorheat exchanger 715. As discussed above the directions 750, 755 ofrefrigerant flow through the first and second reversing ports 214, 216and coupled transfer lines 134, 136 can be revered by rotating thebaffle 220. The reversing value 100 can be actuated to put the system100 in a cooling mode by rotating the baffle 220 to direct refrigerantfrom the input port to the first reversing port 214, e.g., from thecompressor discharge line 130 to the outdoor heat exchange 710. Thereversing valve 100 can be actuated to put the system 100 in a heatingmode by rotating the baffle 220 to direct refrigerant from the inputport to the second reversing port 216, e.g., from the compressordischarge line 130 to the indoor heat exchange 715.

In some embodiments, such as illustrated in FIG. 7, to facilitate accessto the individual ports and transfer lines coupled thereto, the inputand output ports 210, 212 of the valve 100 are located on opposing sides120, 122 of the valve body 105 (FIG. 1) and the first and secondreversing ports 214, 216 are located on different opposing sides 124,126 of the valve body 105. In some embodiments, again to facilitateaccess, in proximity to the reversing valve, portions of the transferlines proximate to the valve extending away from the valve 100 areconfigured to have substantially perpendicular angles with respect toadjacent lines. For example, in some cases, a long dimension of aportion 760 of the discharge line 130 proximate the value 100 and a longdimension of a portion 762 of the suction line 132 proximate the valve100 (e.g., line lengths within, about ½ foot, or within about 1 foot, insome case), are substantially parallel to each other. For example, insome cases, a long dimension of a portion 764 of the first transfer line134 proximate the value 100 and a long dimension of a portion 766 thesecond transfer line 136 proximate the value 100 are substantiallyparallel to each other. In some cases the long dimension portions 764,766 of the first and second transfer lines 134, 136 bisect the valve 100along an axis 430 (FIG. 4) that is that is substantially perpendicularto an axis 420 that the long dimension portions 760, 762 of thedischarge line 130 and suction line 132, bisect the valve 100 along.

Embodiments of the system 700 can further include other components tofacilitate the system's operation. For instance, the system 100 canfurther include a controller 770 configured to cause the system 100 toswitch between a cooling mode and a heating mode. For instance, thecontroller can be configured to actuate the reversing valve 100, e.g.,by controlling the voltage applied to the one or more electromagnets330. In some cases, the controller 760 is further configured to controlthe operation of other components of the system 700, such as thecompressor 132. Embodiments of the controller 770 can includeelectronic, mechanical and electro-mechanical devices, such asmicroprocessors, microcontrollers, state machines, relays, transistors,power amplifiers or passive electronic devices.

For instance, embodiments of the system 100 can further include checkvalves 780, 782, Expansion values 784, 786 and filter/drier 788. Oneskilled in the art would be familiar with the operation and integrationof these and other components to facilitate the system 100 to functionefficiently as a heat pump.

Another embodiment of the present disclosure is a method ofmanufacturing a reserving valve, such as any of the valves 100 discussedin the context of FIGS. 1-7. FIG. 8 presents a flow diagram of anexample method 800 of manufacturing a reserving valve of the disclosure,including any of the example embodiment valve 100 discussed in thecontext of FIGS. 1-7.

With continuing reference to FIGS. 1-7 throughout, the example method800 comprises a step 810 of providing a valve body 105. The body 105 hasan internal cavity 205 therein and an input port 210, output port 212and first and second reversing ports 214, 216. The input port 210, theoutput port 212 and the first and second reversing ports 214, 216 areall in fluid communication with the internal cavity 205.

The method 800 also comprises a step 815 of providing a baffle 220configured to fit within the internal cavity 205 of the valve body 105.The baffle 220 is configured to rotate around a pivot point 225 withinthe internal cavity 205. The ends 305, 307 of the baffle 220 bothcontact interior walls 310, 312 of the value body 105 when the baffle220 rotates about the pivot point 225 in a clockwise direction, therebyisolating the input port 210 and first reversing port 214 and volume 320of the internal cavity 205 there-between, from the output port 212 andsecond reversing port 216 and different volume 322 of the internalcavity 205 there-between. The ends 305, 307 of the baffle 220 contactdifferent interior walls 314, 316 of the value body 105 when the baffle220 rotates about the pivot point 225 in a counter-clock wise direction,thereby isolating the input port 210 and the second reversing port 216and second volume of the internal cavity 324 there-between from theoutput port 212 and the first reversing port 214 and second differentvolume 326 of the internal cavity 205 there-between.

The method 800 further comprises a step 820 of coupling at least oneelectromagnet 330 to the valve body 105. The electromagnet 330 isconfigured to cause the baffle 202 to rotate in one of the clockwisedirection or counter-clock wise direction when a voltage is applied tothe electromagnet 220.

In some embodiments, providing the valve body 105 in step 810 caninclude a step 830 of forming the valve body 105. For instance, formingthe 105 in step 830 can include forming (step 832) two separate halves140, 142 of the body 105. For instance, a metal piece such as copper,brass, aluminum can be bent, machined or molded, as part of step 830, toform the valve body halves 140, 142. In some cases, the forming step 830includes (step 834) forming recesses 230 in one or more the interiorwalls 310-316, the recessed portions 230 of the walls 310-316 configuredto allow portions of major surfaces 335 of the baffle 220 near the ends305, 307 of the baffle 220 to contact the recessed portions 230.

In some embodiments, the forming the body 105 in step 830 can include astep 836 of forming the input and output ports 210, 212 on opposingsides 120, 122 of the valve body 105, and, a step 838 of forming thefirst and second reversing ports 214, 216 on different opposing sides124, 126 of the valve body 105.

In some embodiments the step 815 of providing the baffle 220 can furtherinclude a step 840 of forming the baffle 220. Forming the baffle 220 caninclude bending, machining or molding a material, such as aferromagnetic metal or a non ferromagnetic material, to conform to thesurface contours of the internal cavity 205. For example, the baffle 220can be formed in step 840 such that ends 305, 307 of the baffle 240, inparticular the edges 340, closely match and conform to the surfacecontours of the internal cavity with a gap distance 345 between outeredges of the baffle and the interior walls is about ⅛ inch or less, andin some cases, about 1/16 inch or less. In cases where the baffle 220 issubstantially composed of a non-ferromagnetic material, forming thebaffle 220 (step 840) can further include a step 845 of attached aferromagnetic material 360 to the substantially non-ferromagneticmaterial of the baffle body 365. In some embodiments, forming the baffle220 (step 840) can further include a step 850 covering at least edges340 of the baffle 220 (and in some cases the entire baffle 220) with apliable material 350, such that when connected to the pivot point 225the edge 340 can contact, but still slide, along the interior walls310-316.

Some embodiments of the method 800 can further include a step 855 ofconnecting the baffle 220 to one or more the interior walls (e.g., a topor bottom wall) at the pivot point 225, and step 860 of sealing thevalve body (e.g., by welding or gluing the two halves 140, 142 of thebody 105 together) with the baffle 220 therein.

Those skilled in the art to which this application relates willappreciate that other and further additions, deletions, substitutionsand modifications may be made to the described embodiments.

The invention claimed is:
 1. A reversing valve, comprising: a valve bodyhaving a single internal cavity therein and an input port, output portand first and second reversing ports, wherein the input port, the outputport and the first and second reversing ports are all in fluidcommunication with the single internal cavity; a baffle located withinthe single internal cavity, wherein: the baffle is configured to dividethe single internal cavity into flow paths and rotate around a pivotpoint within the single internal cavity, wherein ends of the bafflecontact interior walls of the single internal cavity when the bafflerotates about the pivot point in a clockwise direction, therebyisolating the input port and first reversing port and volume of thesingle internal cavity there-between, from the output port and secondreversing port and different volume of the single internal cavitythere-between; and the ends of the baffle contact different interiorwalls of the interior walls of the single internal cavity when thebaffle rotates about the pivot point in a counter-clock wise direction,thereby isolating the input port and the second reversing port andsecond volume of the single internal cavity there-between from theoutput port and the first reversing port and second different volume ofthe single internal cavity there-between; and at least one electromagnetcoupled to the valve body; wherein, responsive to a voltage beingapplied to the electromagnet, the electromagnet rotates the baffle in afirst direction; wherein the pivot point is connected to a torsionspring concentric to the pivot point, and wherein the torsion spring isconfigured to rotate the baffle in a direction opposite the firstdirection; and wherein the input and output ports are located oppositeone another on the valve body and the first and second reversing portsare located opposite one another on the valve body.
 2. The reversingvalve of claim 1, wherein one or more of the interior walls of thesingle internal cavity includes a recess, each recess configured suchthat a portion of a major surface of the baffle near one of the ends ofthe baffle can contact the recess and thereby stop the baffle rotationin the clockwise direction or counter-clock wise direction and form afluid seal between the baffle and the interior wall.
 3. The reversingvalve of claim 1, wherein a gap distance between outer edges of thebaffle and the interior walls is about ⅛ inch or less.
 4. The reversingvalve of claim 1, wherein at least an outer edge of the baffle iscovered with a pliable material that contacts the interior walls.
 5. Thereversing valve of claim 1, wherein the single internal cavity of thevalve body is covered with a pliable material.
 6. The reversing valve ofclaim 1, wherein the baffle is substantially composed of a ferromagneticmaterial.
 7. The reversing valve of claim 1, wherein the baffle issubstantially composed of a non-ferromagnetic material and furtherincludes a ferromagnetic material attached thereto.
 8. The reversingvalve of claim 1, wherein the pivot point is substantially offset fromthe center of the single internal cavity along a central axis along theinput port and the output port.
 9. The reversing valve of claim 1, wherethe electromagnet is a first electromagnet, and further including asecond electromagnet coupled to the valve body and configured to rotatethe baffle in the direction opposite the first direction when thevoltage is applied to the second electromagnet and the voltage is notapplied to the first electromagnet.
 10. The reversing valve of claim 1,further including a plurality of electromagnets each coupled to thevalve body, wherein a first set of the electromagnets are configured torotate the baffle in the first direction when the voltage is applied tothe first set of the electromagnets and the voltage is not applied to asecond set of the electromagnets, and the second set of theelectromagnets arc configured to rotate the baffle in the directionopposite the first direction when the voltage is applied to the secondset of the electromagnets and the voltage is not applied to the firstset electromagnets.
 11. The reversing valve of claim 10, wherein thefirst set of electromagnets includes the electromagnet and a secondelectromagnet diagonally opposed to the electromagnet, and, the secondset of electromagnets includes a third electromagnet and a fourthelectromagnet diagonally opposed to the third electromagnet.
 12. Thereversing valve of claim 1, wherein the input port is configured to becoupled to a refrigerant discharge line from a compressor, the outputport is configured to be coupled to a refrigerant suction line of thecompressor, and the first and second reversing ports are configured tobe coupled to an indoor heat exchange coil and an outdoor heat exchangecoil, respectively.
 13. A heat pump system, comprising: an indoor heatexchanger; an outdoor heat exchanger; a compressor configured tocompress a refrigerant and configured to transfer the refrigerant to adischarge line of the system and to receive the refrigerant from asuction line of the system; the reversing valve of claim 1, wherein theinput port is coupled to the discharge line, the output port is coupledto the suction line, the first reversing port is coupled to a firsttransfer line connected to the outdoor heat exchanger, and the secondreversing port is coupled to a second transfer line connected the indoorheat exchanger.
 14. The heat pump system of claim 13, wherein the inputand output ports are located on opposing side of the valve body and thefirst and the second reversing ports are located on different opposingsides of the valve body.
 15. The heat pump system of claim 14, wherein,portions of the discharge line and suction line in proximity to thevalve bisect the valve along an axis that is perpendicular to anotheraxis along which the first and second transfer lines in proximity to thevalve, bisect the valve.
 16. A method of manufacturing a reversingvalve, comprising: providing a valve body having a single internalcavity therein and an input port, output port and first and secondreversing ports, wherein the input port, the output port and the firstand second reversing ports are all in fluid communication with thesingle internal cavity, wherein the input and output ports are locatedopposite one another on the valve body and the first and secondreversing ports are located opposite one another on the valve body;providing a baffle configured to fit within the single internal cavity,such that: the baffle is configured to divide the single internal cavityinto flow paths and rotate around a pivot point within the singleinternal cavity, wherein ends of the baffle both contact interior wallsof the single internal cavity when the baffle rotates about the pivotpoint in a clockwise direction, thereby isolating the input port andfirst reversing port and volume of the single internal cavitythere-between, from the output port and second reversing port anddifferent volume of the single internal cavity there-between; and theends of the baffle contact different interior walls of the singleinternal cavity when the baffle rotates about the pivot point in acounter-clockwise direction, thereby isolating the input port and thesecond reversing port and second volume of the single internal cavitythere-between from the output port and the first reversing port andsecond different volume of the single internal cavity there-between;coupling at least one electromagnet to the valve body, wherein,responsive to a voltage being applied to the electromagnet, theelectromagnet rotates the baffle in a first direction; and providing atorsion spring concentric to the pivot point, wherein the torsion springis configured to rotate the baffle in a direction opposite to the firstdirection.
 17. The method of claim 16, further comprising: forming theinput and output ports on opposing sides of the valve body; and formingthe first and second reversing ports on different opposing sides of thevalve body.
 18. The method of claim 16, further comprising: connectingthe baffle to the interior walls at the pivot point; and sealing thevalve body with the baffle therein.
 19. The system of claim 13, whereinone or more of the interior walls of the single internal cavity includesa recess that can contact a portion of a major surface of the bafflenear one of the ends of the baffle and thereby stop the baffle rotationin the clockwise direction or counter-clock wise direction and form afluid seal between the baffle and the interior wall.
 20. The method ofclaim 16, wherein one or more of the interior walls of the singleinternal cavity includes a recess that can contact a portion of a majorsurface of the baffle near one of the ends of the baffle and therebystop the baffle rotation in the clockwise direction or counter-clockwisedirection and form a fluid seal between the baffle and the interiorwall.